Modules
Many modules, one system, connected through Action Planning.
Each module reaches the plan one of three ways: it raises an owned action, produces a KPI result the plan is judged by, or sets the shift the plan is worked in.
- OperationsKPI results · OEE, Unplanned DT %, Stops
- Autonomous MaintenanceKPI results · CIL Completed %, CL On-Target %
- Preventative MaintenanceShift · work orders due
- Loss EliminationActions · RCA corrective actions
- QualityKPI results · RFT
- Production ExecutionShift · checks on the running order
- SafetyActions and KPI results · incidents, MSVs
- PeopleShift · teams, who is away
- Supply StreamShift · window, team, orders, outages
- InventoryShift · materials for the orders
One plan of owned actions.
Arrives as
- Raises owned actionsfrom Loss Elimination, Safety
- KPI results, judged against Goalsfrom Operations, Autonomous Maintenance, Quality, Safety
- Sets the shiftfrom Preventative Maintenance, Production Execution, People, Supply Stream, Inventory
- Line
- Department
- Plant
- Site
Escalate in one click. De-escalate back to where it started, never lower.
Every actionOwner · Due date · Type · Board · Status
Shows up on
Line Action PlanMy tasksVera briefingShift HandoverProduction Dashboard
Where to start
Start with the Core 4.
These four close the loop on one line on their own.
Operations
Sees the lossWhat ran, what stopped and which machine stopped it, against the shift's goals.
In one loss
Fri Oct 9 · 17:42 · Shift B. Filler · Jam at infeed starwheel · Unplanned · 47 min. The stop is long enough to prompt Start RCA.
Production DashboardLoss Elimination
Finds the causeA long stop opens a root cause analysis, and the analysis ends in an owned action.
In one loss
RCA #219. 6W2H, Fish Bone and Why-Why end at: changeover checklist has no starwheel size verification step.
Root Cause AnalysisAction Planning
Owns the fixEvery miss gets an owner, a due date and a board, and climbs a tier when it needs to.
In one loss
#4190 Add starwheel size check to changeover checklist. Luis Ortega, created Mon Oct 12, due Thu Oct 15.
Line Action PlanAutonomous Maintenance
Holds the standardCILs, centerlines and changeover steps that keep equipment at base condition, due on every shift.
In one loss
When #4190 is done, the size check is a step on the Changeover Task List, so the next changeover runs it.
Changeover Task List
Every module
Every module, by what it puts on the plan.
Each card says what the module feeds the plan with and what it does.
Core 4where we suggest you start
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01
Action Planning
Plan
Action Planning is the plan.
The plan itselfevery module ends here
KPI results, root cause analyses, safety incidents, Management Safety Visits and project tasks land here as owned actions.
What it does
One plan for every owned action, on Line, Department, Plant and Site boards.
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02
Operations
Production & downtime
Feeds the plan with
OEEUnplanned DT %StopsPC Completion %
KPI results judged against your Goals, and the long stops that prompt a root cause analysis.
What it does
Collects production and downtime from a collector at the machine or the line tablet, and puts the shift's targets where operators work.
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03
Autonomous Maintenance
Equipment care
Feeds the plan with
CIL Completed %CL On-Target %Defects FoundChangeover over Std %
KPI results, and the checks each shift owes its equipment.
What it does
Holds equipment at base condition with the checks, standards and changeovers operators run every shift.
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04
Loss Elimination
Problem solving
Feeds the plan with
6W2H Count
Corrective actions with an owner and a due date, linked back to the RCA.
What it does
Takes a repeat loss from a clear problem statement to its root cause, and ends in an owned action.
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05
Preventative Maintenance
Equipment care
Feeds the plan with
Sets the shiftwork orders due
The work orders due on each line this shift, with a planned date and an assignee.
What it does
Plans, assigns and records maintenance work on a multi-level asset register.
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06
Quality
Quality & execution
Feeds the plan with
RFT
KPI results on how batch records move.
What it does
Keeps batch records traceable and moving, from the line to review.
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07
Production Execution
Quality & execution
Feeds the plan with
Sets the shiftchecks on the running order
The checks due on the running order, with the crew notified when one arrives.
What it does
Runs process-based orders step by step, with the checks that arrive on schedule.
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08
Safety
Permits, incidents and safety visits
Feeds the plan with
IncidentsMSVSEEWork Permits
Owned follow-ups from incidents and Management Safety Visits, and KPI results.
What it does
Shows every line's pre-shift readiness color on one Plant Safety Board, beside work permits, incidents and safety visits, with an owner for every follow-up.
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09
People
Teams, attendance and skills
Feeds the plan with
Sets the shiftteams, who is away
The team on each shift, and who is away from it.
What it does
Keeps teams, attendance and skills on record, so leads know who is on and who is trained.
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10
Supply Stream
Scheduling
Feeds the plan with
Sets the shiftwindow, team, orders, outages
The shift itself: its window, its team and its orders. Every other module's due work keys on it.
What it does
Sets the shift: when each line runs, which team is on and which orders run next.
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11
Inventory
Materials
Feeds the plan with
Sets the shiftmaterials for the orders
The material records production orders draw on, so what was used is booked against the order.
What it does
Tracks materials from goods receipt to the line: what you have, where it is and where it went.
See the modules work one shift.
Bring one line and its shift pattern. We'll show you which modules it needs and where each one meets the plan.